I have a set of D2S bulbs and ballasts, and projectors from a Maxima but I think the projector housings are too big. So I was thinking use 90mm Hella projectors like done here:
https://ls1tech.com/forums/appearanc...jectors-6.html
Will my D2S bulbs work in the projector housings? and how hard is it to mount them? I'd like some info before I go and buy them and attempt this!

 

Since you started a thread on this as well...

Here the bulk of the PM response I sent:

The fog light location is too low for a low beam.

Here is some more on using the Hella 90mm projector on the 1993-1997 Camaro:
http://bellsouthpwp.net/m/u/mulgeary/Hella90/

HibachiZ28's setup using Hella 90mm H9 projectors:
https://ls1tech.com/forums/appearance-detailing/931991-projectors-finally-installed.html
http://www.hidplanet.com/forums/viewtopic.php?t=41988
http://www.hidplanet.com/forums/viewtopic.php?t=43963
http://www.hidplanet.com/forums/viewtopic.php?t=42344
http://www.hidplanet.com/forums/viewtopic.php?t=42298


Check out HID Planet /forums/ for plenty of information on this very topic. I'm on there with the same name and HibachiZ28 is on there with his old screen name GhostDakota (I think). On there you can find plenty of retrofits using various projectors on various cars.

If you want to use the Hella 90mm projector, there are four options:
1) Get the H9 version and modify it to fit D2S
2) Get the H7 version and modify it to fit D2S
3) Get the H7 version and use an adapter plate (from ebay) to fit D2S
(the bulb hole probably still needs to be groved for the return wire, I don't remember)
4) Get the D2S version...which is nearly triple the cost
(Option 3 is the most cost effective since you already have D2S bulbs and ballasts, but Option 4 should have better output.)

Otherwise, there are better D2S HID projectors available, but they aren't sealed like the Hella 90mm. You'd have to make a housing for them. How big are the Maxima projectors that you have? You can find the Hella 90mm's dimensions on Rally Lights.

If you go with the Hella 90mm, you might want o make custom curved shields to improve the beam pattern. Check out my install (scroll down to post #4 for the curved shield).
https://ls1tech.com/forums/appearanc...leny-pics.html

I did some digging and found a page that still had pictures depicting a Hella 90mm modified to fit D2S. Most of what I had previously, the pictures are missing or the entire page is now missing. There was a good thread on a Z3 forum about aligning the D2S capsule in the projector for the best output. If I can find it again, I'll post it.

This page talks about the Hella 90mm and even shows converting it to use D2S:
http://faqlight.carpassion.info/hella-90mm/
(Scroll down for pics and info.)

I found more on modifying the Hella 90mm to use D2S:
http://hanker.tripod.com/headlight-l...-beam-mods.htm

DirtyBird222 has the H7 version and used an adapater plate (available on ebay and elsewhere) to install D2S. His setup is listed in the Lighting FAQ. Here is a direct link:
dirtybird222's setup using Hella 90mm H7 projectors with H7-to-D2s adapters:
https://ls1tech.com/forums/appearance-detailing/866146-appearance-update-new-headlights-calipers-painted.html
https://ls1tech.com/forums/appearance-detailing/875992-progression-my-car-56k-get-real.html
http://www.hidplanet.com/forums/viewtopic.php?t=39795
http://www.hidplanet.com/forums/viewtopic.php?t=39549

 

I found this discussion about putting D2S into the Hella H9 90mm:
http://www.network54.com/Forum/21646...lso+Hella+90mm
It mentions fine-tuning bulb placement.
It also has pics of the modified base.

 

Haha thanks for both of your responses I figured a thread would be helpful to have more than one person chime in after I sent my pm. I'm leaving my factory hi/lo beams alone and just want to use the projectors for fogs like "TheGr8Schlotzky" did on his Camaro. I just need some info on how to mount them and position them to get the results he did.

 

Low beam lights in a fog light position won't have enough side to side spread. You really need a foglight down low.

 

If you intend to use the Hella 90mm as a fog light only, you can make your own custom cut-off shield without the step. That will produce a flat line typical of a fog light beam pattern. If you go that route, line up the new shield with the taller side of the step in the old shield. This may sound odd, but the shield pattern is actually flipped on the wall, so the high side of the shield is the low side of the beam on the wall. Also slot the holes in the new shield to allow for adjustment. You want the bulb to still be covered by a similar amount as the old shield. If you uncover the bulb, you'll get a hot spot in the middle of the beam and a burst pattern over the cut-off line. Then comes the reason for the slotted holes. You can adjust the shield up/down (and tilt back/forth) to give the sharpest line with the best output and width. Check out my install thread for more info.

 

Cool thanks so if I get the 90mm projectors i basically just need to make a piece of scrap aluminum to attach to the existing shield on the top line, and get an adapter to fit my D2S bulb in the H7 housing off ebay. Will this adapter set the bulb further back in the projector housing and throw off the beam pattern though?

 

You can make your own custom shield instead of attaching to the stock one. That way you can always return to it if you want. Here is mine:
https://ls1tech.com/forums/10827087-post4.html
Some people have attached aluminum to the stock shield, but I prefer a less permanent solution.

I don't know what effect the adapter plate has on bulb placement if any. Check out dirtybird222's setup. He used the adapter plate. The fourth link above is a thread he started about some difficulty he had with it. If you PM him, maybe he can post some pics.

 

Here is an example of the "H7 to D2S" adapter:
http://cgi.ebay.com/ebaymotors/H7-to...Q5fAccessories





BTW, that is a different projector, not the Hella 90mm.

 

Nice idea..

anyone build for 2001 Camaro headlight?
I found post for Camaro>>
https://ls1tech.com/forums/western-m...ave-again.html

 

Well, I have two Maxima Projector housings that maybe I can modify. Do you think those will be too big? Getting the bulb to fit and modify the cut off on the 90mm is not a big deal I just need to find out how to mount the 90mm's in the foglight positions. I'll have to PM TheGr8Schlotzky.

 

I don't know how big they are, but you'll have to build housings to encase them. They are not sealed.

 

Yes, look in the Lighting FAQ.

Also, for the 1998-2002 Camaro, I'd recommend a different projector such as TSX, FX, RX330, S2K, etc... those are real HID projectors using D2S bulbs (of that list TSX is probably the easiest to work with). They are not sealed, meaning they are intended to be inside a housing which is fine since the 1998-2002 Camaro has housings in which you can install them.

 

The great part about the Hella 90mm projectors is the they came with all the mounting hardware and brackets to mount them to any flat surface. You'll find that if you take off the front bumper, the metal frame is the perfect area to mount the lights, and the stock wiring harness comes through two holes that are in this bar. You'll need to increase the size of this hole by a fairly large margin to fit the 90mm's in there, but it's plenty doable. I used a air cutoff wheel to get the right size and rough shape, but you'll notice the finished product in my thread was not perfectly aimed. This was beacuse in order to get the 90mm's to fit with my cutoff wheel, the hole had to be rather hexagonal, and it really needs to be round. What I'd recommend, and what I end up buying was a air die grinder and a carbide burr. I haven't yet had the time to get my bumper off and go at it, but It's high on the list now and I will be soon. With the burr I'm just going to make the hole a bit more round, and will be able to further utilize the aiming mechanisms on the 90mm's.

If there is anything else you need to know, just let me know. You might want to PM me again as I don't frequent this board, but I do check my email.

 

Awesome thats what I was looking for! So basically all I need to do is modify my bracket by drilling out the mounting holes and drilling a hold so the projector can sit back further inside the bumper. I have a 1/4 die grinder and everything so it should be pretty easy once I get the lights and I can actually see whats going on, right? Did you have to cut any area out of the bumper or modify anything else besides the mounting bracket?

 

For cross-reference, here is the HID Planet version of this thread:
http://www.hidplanet.com/forums/viewtopic.php?t=46908

 

No modifications to the bumper cover, it flexes enough to allow for the lights to fit in, just make sure they go in when you put the bumper back on.

I'm not entirely sure what you said, so I'll clarify.

I removed the stock lights. Housings/brackets, everything. What's left is a hole in the cars bumper (not to be confused with the bumper cover). You make this hole bigger with the burr and drill a few holes for the 90mm's brackets which come attached to the lights. Straight forward from there. But like I said, no modification to the bumper cover at all.

 

Cool thanks man I took it apart and checked it out today and I'm thinking I might even be able to use my OEM Maxima projectors in there if I can figure out a way to mount them. Where did you end up mounting your ballasts? Mine aren't sealed :x

 

I'm not sure if it gets wet or not, it's all weatherproof, so I didn't worry about it.